Electrical block

ABSTRACT

There is provided an electrical block, which cures those deficiencies outlined above of providing a mount, and a separate electrical box. The mount has a base that is adapted to be secured to an exterior surface of a structure. The mount also has a housing extending from the base that has an opening formed therein to receive an electrical box. The electrical box includes a base, plurality walls extending from the base. The walls have an upper portion, which is received in the opening of the housing such that the electrical box is securely retained. One of the walls of the electrical box defines a second opening formed within the electrical box.

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application is a continuation-in-part of U.S. Ser. No.09/342,572, filed Jun. 29, 1999, and also assigned to TapcoInternational Corporation.

BACKGROUND OF THE INVENTION

[0002] This invention generally relates to a multi-piece electricalblock for use on an exterior surface of a structure. The assemblysupports an electrical outlet or other electrical fixture and is adaptedto be used with siding or another exterior surface covering.

[0003] Electrical blocks have been developed in the past for use on theexterior surfaces of a structure. The prior electrical blocks attempt toprovide a decorative means of attaching an electrical fixture or outletin a functional manner to structures having an uneven surface, such as asurface to which aluminum or vinyl siding has been attached. Knownelectrical blocks typically have a mount that is attached directly tothe structure. Siding or other decorative covering is then attached tothe structure around the mount. A decorative ring or covering may beused which may be either integral with the mount or a separate piece, tocover the edges of the siding that are adjacent to the mount to providea more aesthetically pleasing appearance. In the art prior to applicantscopending application as cross-referenced above, an electrical block haseither been integrally formed with the mount or the electrical block hasbeen required to be at least partially recessed into the surface of thestructure. These configurations have been found to be deficient.

[0004] Electrical box assemblies which are required to be disposed atleast partially recessed into the surface of the structure areinconvenient because the hole in the structure that receives theelectrical box must be placed in a position in which it does notinterfere with the supporting structure underlying the surface.

[0005] Designs having electrical boxes that are integrally formed withthe mount typically cannot be molded utilizing a plastic material thathas good weatherability and color characteristics while providing adesign that meets electrical block safety requirements, such as thosefound in many housing codes.

[0006] Previous electrical block assemblies have not included anelectrical box wherein the underlying box portion is largerdimensionally than the opening. Another manner of defining this featureis that at least one of the walls of the box does not align with theexterior opening of the block, in order to accommodate fixtures that aretoo large for electrical boxes having only having walls aligned with theopening.

[0007] Accordingly, it is an object of the present invention to providea multi-piece electrical block that has an electrical box which canaccommodate various fixtures through either a first or a second openingformed in the electrical box, and which includes an underlying boxportion that is dimensionally larger than the exterior opening of theblock. It is also an object of the present invention to provide amulti-piece electrical block that has good weatherability and coloredcharacteristics as well as provides an electrical box that meetssuggested safety standards.

SUMMARY OF THE INVENTION

[0008] There is provided an electrical block which cures thosedeficiencies outlined above by providing a mount and a separateelectrical box. The mount has a base that is adapted to be secured to anexterior surface of a structure. The mount also has a housing extendingfrom the base with an opening formed receive an electrical box. Theelectrical box includes a base, a plurality of walls extending from thebase, and a mechanism for connecting the electrical box to the base. Theelectrical box is dimensionally larger than the exterior opening of thebase to extend beyond the opening and behind the exterior wall of thebase. One of the walls of the electrical box defines a second openingformed within the electrical box.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The various advantages of the present invention will becomeapparent to one skilled in the art by reading the followingspecification and claims and by referencing the following drawings inwhich:

[0010]FIG. 1A is an exploded perspective view of the electrical block ofthe present invention;

[0011]FIG. 1B is a perspective view of a first embodiment of the presentinvention assembled;

[0012]FIG. 2 is a partial perspective view of a first embodiment of amount of the present invention attached to an exterior surface to whichsiding is attached; and

[0013]FIG. 3 is an enlarged perspective view of a first embodiment of anelectrical box of the present invention.

[0014]FIG. 4 is an exploded perspective view of a second embodiment ofthe rear of the electrical block of the present invention;

[0015]FIG. 5 is an exploded perspective view of a second embodiment ofthe front of the electrical block of FIG. 4;

[0016]FIG. 6 is a perspective view of a second embodiment of theelectrical block when assembled;

[0017]FIG. 7 is an elevational view with sections blown away of a secondembodiment of the assembled electrical block installed on the side of abuilding structure;

[0018]FIG. 8 is a perspective view of a second embodiment of theelectrical box separate portion of the electrical block of the presentinvention;

[0019]FIG. 9 is a perspective view of a second embodiment of thebackside of the electrical box separate of the electrical block of thepresent invention; and

[0020]FIG. 10 is a perspective view of a second embodiment of thebackside of the assembled electrical block of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0021] Referring to FIGS. 1A and 1B, a first embodiment of an electricalblock trim assembly 10 for use on an exterior surface of a structure isshown. The assembly 10 has three main components: a mount 12, adecorative ring 14, and an electrical box 16. The mount 12 has a base18, or lower portion, from which a flange 20 extends. The flange 20 hasa plurality of holes 22 adapted to accommodate fasteners which are usedto attach the mount 12 to the exterior surface. A rectangular housing 24is defined by a plurality of side walls 26 that extend from the base 18.Although using a rectangular shaped housing simplifies installation ofsiding around the assembly, it is to be understood that the housing canbe any desired shape.

[0022] The housing 24 has a top portion 28 disposed between the sidewalls 26 opposite from the base 18. The top portion 28 has an opening 30and a ledge 32 formed about the opening 30, which is best shown in FIG.2. With continuing reference to FIGS. 1A and 1B, the housing 24 has anouter surface 36 with opposing portions 38 on opposite side walls 26,only one of which can be seen in the Figures. Each of the portions 38has grooves 40 that are adjacent to one another and that run parallel tothe base 18. The ledge 32 forms a first interlocking member that is usedto secure and retain the electrical box 16 to the mount 12, as describedin detail below.

[0023] The decorative ring 14 is secured to the mount 12 over the sidingto conceal the edges, as best shown in FIG. 2. With continuing referenceto FIG. 1A and 1B, the decorative ring 14 has an rectangular innerperimeter 42 that corresponds to the contour of the housing 24. Theinner perimeter 42 has opposing protrusions 44, only one of which can beseen in the Figures, that are aligned with the grooves 40 so that theprotrusions 44 interlock with the grooves 40 when the decorative ring 14is installed over the mount 12.

[0024] The electrical box 16 is secured to the mount 12 duringinstallation of the assembly 10. The electrical box 16 has walls 46 witha bottom portion 48 disposed between lower portions of the walls 46,which form a cavity 47 to accommodate wires and other electricalcomponents. At least one knock-out 49 is provided on the bottom portion48 so that the knock-out 49 may be removed and wires may be passedthrough the resulting opening and into the electrical box cavity 47.

[0025] The electrical box 16 has a second interlocking member thatcoacts with said first interlocking member and secures said electricalbox to the mount 12. As best shown in FIG. 3, the walls 46 have an upperportion 52 with a lip 54 that is securely received and retained withinthe opening 30 and supported by the ledge 32. The upper portion 52 hasat least one tab 56 that is proximate to the lip 54. The ledge 32 formsthe first interlocking member and the lip 54 and at least one tab 56form the second interlocking member. The tabs 56 secure the electricalbox 16 to the mount 12 by receiving the ledge 32 between the lip 54 andthe tabs 56. In this manner, the electrical box 16 is snapped into theopening 30 in the mount 12. However, it is to be understood that theelectrical box 16 may be retained in the opening 30 using any suitablemechanism. For example, a different interlocking configuration may beused, or an interference fit between the electrical box 16 and opening30 may be used.

[0026] Since the mount 12 and the electrical box 16 are separatecomponents of the assembly 10, they may be constructed from differentplastic materials. This enables plastic materials having differentcharacteristics to be used. For example, a plastic suitable forelectrical boxes may be used when constructing the electrical box, and aplastic suitable for molding in wide variety of colors and which hasgood weatherability may be used for the mount 12 and decorative ring 14.

[0027] Returning now to FIG. 2, exterior covering 13, such as siding 13,surrounds a portion of said mount. The electrical box 16 is interposedbetween the exterior surface and said top portion.

[0028] Referring to FIGS. 4 through 9 there is shown a second embodimentof an electrical block 110 for use on an exterior surface. Theelectrical block 110 as described has three major components: a base112, an electrical box 114, and a trim ring 116. The base 112 includes aflange 120 which has a plurality of holes 122 adapted to accommodatefasteners which are used to attach the base 112 to the exterior surfaceof a building structure. The base further includes a plurality ofsidewalls 126, and a top exterior wall 124 disposed between thesidewalls 126. Although the depicted embodiment shows a rectangularshaped housing, it is to be understood that the block 110 may be ofother shapes without departing from the inventive aspect of the presentinvention. The base may also include reinforcement ribs or structures tomeet specific safety standards that may be required.

[0029] With reference to FIGS. 4 and 5, the top exterior wall 124 has anopening 130 and an edge 132 formed about the opening 130. The opening130 may be centered or offset in relation to the top exterior wall 124depending upon the specific application. The edge 132 forms a firstinterlocking member that is used to secure and retain the electrical box114 to the mount 112. The connection and retention of the electrical box114 to the base 112 will be described in more detail below. Again, withreference to FIGS. 4 and 5, the base 112 has at least two opposingportions 138 located on opposite sidewalls 126. Each of these portions138 has grooves 140 that are adjacent to one another and that runparallel to one another.

[0030] A decorative trim ring 116 may be secured to the base 112 oversiding or exterior covering 113 to conceal the flanges 120 as best shownin FIG. 7. The decorative trim ring 116 has an inner perimeter 142 thatcorresponds to the contour of the base 112. The inner perimeter 142 hasopposing protrusions 144 that are alignable with the grooves 140 so thatthe protrusions 144 interlock with the grooves when the decorative ring116 is installed over the base 112. By providing multiple adjacentgrooves 140, the decorative ring 116 may be installed over siding orother exterior coverings of various thicknesses, substantially asdescribed in U.S. Pat. No. 4,920,708.

[0031] The electrical box 114 is secured to the base 112 during assemblyof the block 110. With reference to FIGS. 8 and 9, the electrical box114 has a bottom wall 148 disposed between sidewalls 146 which form acavity 147 to accommodate wires and other electrical components. One ofthe sidewalls 146 defines a second opening, which leads to anothercavity 149. The walls 150, define another cavity 149. The walls 150further define an access opening 155, which has a lid 199. As can beseen, the access opening 155 is parallel to the base 148 of the box 114.The lid 199 covering the access opening includes a latch mechanism 154for holding the lid 199 in place or for releasing the lid 199 whenaccess is desired. There is also included at least one knock out 155provided on the bottom portion 148 such that the knock out may beremoved and wires may be passed through the resulting opening and intothe electrical blocks cavity 147.

[0032] The electrical box 114 has a second interlocking member 156 thatinteracts with the first interlocking member 132 formed in the housing124 and secures the electrical box 114 to the mount 112.

[0033] With reference to FIGS. 8 and 9 the walls 146 have an upperportion 157 with a lip 158 that is securely received and retained withinopening 130 and supported by the ledge 132. The upper portion 157 hasattachment portions 159 with holes 167 to which electrical fixtures maybe attached.

[0034] The upper portion 157 has at least one tab 169 that is proximateto the lip 158. The ledge 132 forms the first interlocking member andthe lip 158 and at least one tab 169 form the second interlocking member156. The tabs 169 secure the electrical box 114 to the mount 112 byreceiving the ledge 132 between the lip 158 and the tabs 169. In thismanner, electrical box 114 is snapped into the opening 130 in the mount112.

[0035] With reference to FIG. 7, the invention provides an improvedmethod of installation. A hole 160 is laid in a surface 161 of astructure 162 through which electric wires 164 are fed. The mount 112 issecured to the surface 161 by a plurality of fasteners 170 disposedwithin the holes 122. An exterior covering or siding 113, is installedon the surface 161 surrounding a portion of the mount 112. Thedecorative ring (not shown) is installed over the siding 113 and securedto the mount by the protrusions 144 and grooves 140. The electrical box114 is snapped into the opening 130 so that it is positioned between theexterior surface 161 and the top surface 148. The first and secondinterlocking members 132 and 156, respectively, secure the electricalbox 116 to the mount 112. The wires 164 are received in a cavity 149provided by the second plurality of walls 150 or through a removed knockout 155.

[0036] Because the mount 112 and the electrical box 114 are separatecomponents of a multi-piece electrical box 110 they may be formed fromdifferent plastic materials. This relationship allows the electrical boxto be molded from one plastic material while the mount 112 may be madewith an alternative plastic material. Again, this would allow for aplastic material that meets specifications for electrical boxes to beused, while another plastic material that displays improvedcharacteristics as to weatherability and maintaining its color may beused for the mount and decorative ring.

[0037] While preferred embodiments are disclosed, a worker in this artwould understand that various modifications would come within the scopeof the invention. Thus, the following claims should be studied todetermine the true scope and content of this invention.

What is claimed is:
 1. A multi-piece electrical box for attaching to asurface of a structure comprising: a mount having a base adapted to abuta surface; a housing extending from said base, said housing having afirst opening formed therein; an electrical box having a base and aplurality of walls extending from said base, said walls having an upperportion wherein said first opening is sized to receive within andadapted to securely retain at least a part of said upper portion, saidbase extending further than said opening in at least a first directionparallel to a plane formed by said opening; a first of said wallsdefining a second opening therein; and means for securing saidelectrical box to said mount at said opening.
 2. An assembly as setforth in claim 1 , including a second plurality of walls extendingoutwardly from said first wall.
 3. An assembly as set forth in claim 2 ,wherein second plurality of walls is integral with said first wall. 4.An assembly as set forth in claim 2 , wherein said plurality of wallsdefines an access opening.
 5. An assembly as set forth in claim 4 ,wherein said access opening is parallel to said base.
 6. An assembly asset forth in claim 5 , wherein said access opening is complainer withsaid base.
 7. An assembly as set forth in claim 4 , including a lidcovering said access opening.
 8. An assembly as set forth in claim 7 ,including a latch mechanism for holding said lid over said accessopening and for releasing said lid from said access opening.
 9. Anassembly as set forth in claim 7 , wherein said lid is complainer withsaid base.
 10. An assembly as set forth in claim 1 , wherein said mounthas a first interlocking member and said electrical box has a secondinterlocking member adapted to interact with said first interlockingmember and secure said electrical block to said mount when said mountreceives said electrical box.
 11. An assembly as set forth in claim 1 ,further including a decorative ring having an inner perimeter sized toreceive said housing.
 12. An assembly as set forth in claim 10 , whereinsaid housing has an exterior surface with opposing portions, one of saidopposing portions and said inner perimeter of said ring having opposinggrooves and the other of said opposing portions and said inner perimeterhaving opposing protrusions that are aligned with said opposing grooves,wherein said protrusions are adapted to interlock with said grooves whensaid ring receives said housing.
 13. A multi-piece electrical box forattaching to a surface of a structure comprising: a mount having a baseadapted to abut a surface; a housing extending from said base, saidhousing having a first opening formed therein; an electrical box havinga base and a plurality of walls extending from said base, said wallshaving an upper portion wherein said first opening is sized to receivewithin and adapted to securely retain at least a part of said upperportion, said base extending further than said opening in at least afirst direction parallel to a plane formed by said opening; a first ofsaid walls defining a second opening therein and wherein a secondplurality of walls extends outwardly from said first wall; and means forsecuring said electrical box to said mount at said opening.
 14. Amulti-piece electrical box for attaching to a surface of a structurecomprising: a mount having a base adapted to abut a surface wherein saidmount has a first interlocking member; a housing extending from saidbase, said housing having a first opening formed therein; an electricalbox, said electrical box has a second interlocking member adapted tointeract with said first interlocking member, said electrical box havinga base and a plurality of walls extending from said base, said wallshaving an upper portion wherein said first opening is sized to receivewithin and adapted to securely retain at least a part of said upperportion, said base extending further than said opening in at least afirst direction parallel to a plane formed by said opening; a first ofsaid walls defining a second opening therein.